WARNING. The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

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3 The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner s manual on the next page. If you cannot locate this card, or if it has been removed, please call for assistance.

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5 Copyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A Sportsman 700 EFI Owner s Manual P/N

6 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. Polaris Recreational Vehicles S Snowmobiles S All-terrain vehicles (ATVs) S Watercraft S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we ve ever produced. For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician. Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period. We also take great pride in our Parts Apparel and Accessories (PAA) products, available through our online store at Have your accessories and clothing delivered right to your door! POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. 3

7 VEHICLE IDENTIFICATION NUMBERS Record your ATV s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced XX 3 Vehicle Model Number: Frame VIN (1): Engine Serial Number (2): Key Number (3): 4

8 TABLE OF CONTENTS WELCOME... 3 VEHICLE IDENTIFICATION NUMBERS... 4 SAFETY... 6 FEATURES AND CONTROLS OPERATION EMISSION CONTROL SYSTEMS MAINTENANCE AND LUBRICATION ADJUSTMENTS TROUBLESHOOTING POLARIS PRODUCTS SPECIFICATIONS WARRANTY INDEX

9 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal. Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS:

10 Safety Decals and Locations SAFETY IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS. (545 kg). Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered, carried as low as possible, and firmly secured to the racks. With dual racks, load distribution 1/3 front 2/3 rear is best. For stability on rough or hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack. Read Owner s Manual for more detailed loading information S S ATTENTION Operation of this vehicle without the air filter element will severely damage the engine. Clean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter

11 SAFETY Safety Decals and Locations S S Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death. NO STEP Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age S DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. S Max Rack Loads: Front 100 lbs. (45 kg) Rear 200 lbs. (91 kg)

12 Safety Decals and Locations Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in AWD. See Owner s Manual ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner s Manual SAFETY MANUFACTURED BY: POLARIS IND. INC. DATE: VIN: THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS. Canadian Certification Decal TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15 GRADE HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68KG)

13 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. Select an approved helmet that meets or exceeds your state s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.1), or the Snell Memorial Foundation label. 2. Eye Protection Do not depend on sunglasses for proper eye protection. A pair of goggles or a helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the markings z2.1 or VESC 8). 3. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection. 4. Boots The best footwear is a pair of strong over-the-calf boots with heels, like moto-cross boots. 5. Clothing Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection

14 Operator Safety SAFETY Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner s manual and all warnings before operating a Polaris ATV. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Know Your Vehicle As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner s manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures. Safety Training When you purchased your new ATV, your dealer offered a hands-on safety training course that covers all aspects of vehicle safety. You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis. If you purchased a used Polaris ATV from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer. A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals. 11

15 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. NOTE: The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. The safety alert warning indicates a potential hazard that may result in serious injury or death. CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION A caution indicates a situation that may result in damage to the vehicle. IMPORTANT IMPORTANT will alert you to important information or instructions. A note will alert you to key information or instructions. 12

16 Operator Safety SAFETY Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner s manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at to find out about the training courses nearest you. S Never allow anyone under 16 years of age to operate this ATV. S Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course. S Always avoid operating an ATV on paved surfaces, including sidewalks, driveways, parking lots, and streets. S Never operate an ATV on a public street, road or highway, including a dirt or gravel road. S Never operate an ATV without wearing an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants. S Never consume alcohol or drugs before or while operating an ATV. S Never operate at excessive speeds. Travel at speeds appropriate for the terrain, visibility and operating conditions, and your experience. S Never attempt wheelies, jumps or other stunts. S Always inspect your ATV before each use to make sure it s in safe operating condition. Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual. S Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation. S Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain conditions. S Never operate on excessively rough, slippery, or loose terrain. S Always follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. 13

17 SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. S Always follow proper procedures for climbing hills. Check the terrain carefully before ascending a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed. S Always follow proper procedures for going downhill and for braking on hills. Check the terrain carefully before you start down a hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible. S Always follow proper procedures for crossing the side of a hill. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you ve mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a steep hill when possible. S Always use proper procedures if you stall or roll backwards while climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following the procedure described in this manual. S Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. S Always be careful of skidding or sliding. On slippery surfaces like ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control. S Avoid operating the ATV through deep or fast-flowing water. If it s unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes. 14

18 SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test the brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operating in reverse. When it s safe to proceed in reverse, move slowly and avoid turning at sharp angles. S Always use the size and type of tires specified for your ATV, and always maintain proper tire pressure. S Never modify an ATV through improper installation or use of accessories. S Never exceed the stated load capacity for your ATV. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at , or call Polaris at Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury. The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power. NOTE: The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle. 15

19 SAFETY Operator Safety POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris. Operators should regularly practice the skills learned in the course and the operating techniques described in the owner s manual. For more information about the training course, contact an authorized ATV dealer or call Polaris at POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Severe injury and/or death could occur if a child under the minimum age recommendation operates an ATV. Even though a child may be within the recommended age group for operating some ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV. 16

20 Operator Safety SAFETY POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers. POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control, accident, and/or injury. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement. If it s unavoidable, travel slowly and avoid sudden turns or stops. 17

21 SAFETY Operator Safety POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it s illegal to operate ATVs on public streets, roads and highways. POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. 18

22 Operator Safety SAFETY POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV. POTENTIAL HAZARD Operating the ATV at excessive speeds. WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV, which can result in an accident causing severe injury or death. HOW TO AVOID THE HAZARD Always operate the ATV at a speed that s proper for the terrain, visibility and operating conditions, and your experience. POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. 19

23 SAFETY Operator Safety POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner s manual. POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator s foot is not firmly planted on the footrest, it could come into contact with the rear wheels and lead to accident or injury. HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation. 20

24 Operator Safety SAFETY POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions. POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain. Always use extra caution on rough, slippery or loose terrain. 21

25 SAFETY Operator Safety POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25_. Practice on smaller hills before attempting large hills. 22

26 Operator Safety SAFETY POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly while traveling uphill. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. 23

27 SAFETY Operator Safety POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual. NOTE: A special technique is required when braking while traveling downhill. See page 57. Always check the terrain carefully before descending a hill. Shift your weight backward. Never travel down a hill at high speed. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible. 24

28 Operator Safety SAFETY POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD NeverattempttoturntheATV around on any hill until you ve mastered the turning technique (on level ground) as described in the owner s manual. See page 58. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill. When crossing the side of a hill: Always follow proper procedures as described in the owner s manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. 25

29 SAFETY Operator Safety POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill. Apply the brakes. Lock the parking brake when fully stopped. If the ATV begins rolling backwards: Keep weight uphill. Never apply engine power. Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount on uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described in the owner s manual. See page

30 Operator Safety SAFETY POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner s manual. POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE HAZARD On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control. 27

31 SAFETY Operator Safety POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water. If it s unavoidable to enter water that exceeds the recommended maximum depth (see page 59), travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes. Wet brakes may have reduced stopping ability. Always test the brakes after leaving water. If necessary, apply them several times to let friction dry out the pads. POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN The ATV could collide with an obstacle or person, resulting in severe injury. HOW TO AVOID THE HAZARD Before shifting into reverse gear, always check for obstacles or people behind the ATV. When it s safe to proceed, back slowly. 28

32 Operator Safety SAFETY POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires, or operation of the ATV with improper or uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV in the owner s manual. Always maintain proper tire pressure as described in the owner s manual and on safety decals. POTENTIAL HAZARD Operating the ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling, which could lead to an accident. HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information. 29

33 SAFETY Operator Safety POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer. POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator fall through the ice. HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water. 30

34 Operator Safety SAFETY Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control, which could result in severe injury or death. CAUTION Exposure to the hot components could result in a fire. Always keep combustible materials away from the exhaust system. 31

35 FEATURES AND CONTROLS Engine Electrical Switches Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open Mode/Reverse Override Switch (1) - This vehicle is equipped with a reverse speed limiter system. To gain additional power while backing, depress the override switch. NOTE: The override switch also allows activation of All Wheel Drive in reverse, if the AWD switch is on. This switch is also used to toggle through the different modes of the rider information center. See page 40. Engine Stop Switch (2) - The engine will not start or run when the switch is in the OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. OFF 2 RUN OFF NOTE: The cooling fan motor does not shut off when the stop switch is used to stop the engine. Turn off the main ignition switch to turn off the cooling fan motor. Main Switch (3) - To start the engine, slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position. Release the key when the engine starts. NOTE: Both the main switch and the emergency engine stop switch will shut off all electrical power to the vehicle, including lights. To stop the engine, slide the stop switch either right or left to the OFF position. Worklight Switch (4) 32

36 FEATURES AND CONTROLS Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine. Also check occasionally during operation. Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever (1). The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease. Modifications to the ETC could result in failure to perform as designed, which could result in severe injury or death. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms. Always ensure that the throttle cable is properly installed to the ETC. 1 33

37 FEATURES AND CONTROLS Light Switches The light switch is located on the left handlebar. It s used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won t work unless the key is in the ON position and the auxiliary shut-off switch is in the RUN position. Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Brake Lever The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs. Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. 1 34

38 FEATURES AND CONTROLS Master Cylinder The brake fluid in the master 1 2 cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear. NOTE: When checking the fluid level, the ATV must be on level ground with the handlebars straight. If the fluid level is low add DOT 3 brake fluid only. See page 107 for the part numbers of Polaris products. After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. 35

39 FEATURES AND CONTROLS Parking Brake Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Place the transmission in park Squeeze and release the brake lever (1) two or three times, then squeeze and hold. 3. Push the park brake lock (2) forward to engage the brake. Release the brake lever. 4. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position. Important Safeguards S The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. S Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position. S Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling. 36

40 FEATURES AND CONTROLS Auxiliary Brake Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death. Your Polaris ATV has an 1 auxiliary brake (1) for added safety. It s located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative. If the rear wheels slide while using the auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding. Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located under the seat or near the auxiliary brake. Maintain the fluid level between the maximum and minimum marks. Fuel Tank The fuel tank filler cap (1) is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Fuel Filter The in-line fuel filter should be replaced by your dealer after every 200 hours of operation and any time the fuel becomes contaminated with dirt or debris. Do not attempt to clean the fuel filter. 1 37

41 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift into HIGH or PARK, you must first apply the auxiliary brake to activate the high/park lock-out mechanism. When shifting out of HIGH or PARK, it s not necessary to apply the brake. 1 H L N R P Whenever the ATV is left unattended, always place the transmission in park and lock the parking brake. CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Apply the auxiliary brake if shifting into HIGH or PARK. Belt Life To extend belt life, use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time. 38

42 FEATURES AND CONTROLS All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, On-Demand All Wheel Drive system, which is activated by the AWD switch (1) on the right handlebar. When the switchisoff,theatvisin two-wheel drive at all times. When the switch is on, the ATV is in AWD and the AWD indicator light in the instrument cluster will be on. When in AWD, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage. NOTE: The override switch allows activation of AWD in reverse if the AWD switch is on. See page 32. There is no limit to the length of time the vehicle may remain in AWD. Engaging the Front Gearcase The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle s electronic system will not enable the AWD until the engine RPM is below Once enabled, the AWD remains enabled until the AWD switch is turned off. If the switch is turned off while the front gearcase is moving, it will not disengage until the rear wheels regain traction. Engage the AWD switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD. CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest. 1 39

43 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7-9 mph. Refer to page 32 for additional information Rider Information Center 2. Speedometer needle - in addition to showing vehicle speed, the needle flashes when a warning condition exists. 3. Speedometer CAUTION High water pressure may damage ATV components. Wash the ATV by hand or with a garden hose using mild soap. Certain products, including insect repellants and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to come into contact with the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 40

44 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the ATV to your Polaris dealer for proper diagnosis. 1. Gear Indicator - As the shift lever is moved, this indicates the gear the transmission is in: H = High Range L = Low Range N = Neutral 7 8 R = Reverse P=Park 2 2. AWD Indicator - This indicator illuminates when the electrical 9 portion of the AWD system is enabled. 3. Engine Hour Display Indicator 1 4. Service Interval/Diagnostic Mode Indicator 5. Low Battery and Over Voltage - This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged. A low battery warning may also occur under normal operation if the machine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Driving at a higher RPM or connecting a battery charger will usually clear the warning. 6. Odometer/Tachometer/Tripmeter/ Hour Meter 7. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments will flash, FUEL will display in the LCD, and the speedometer needle will blink. Refuel immediately. 8. Check Engine Warning Indicator - This indicator serves two purposes. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. Do not operate the ATV if this warning appears. Serious engine damage could result. 9. Mode Indicator 41

45 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode button. NOTE: If using the mode button to program the rider information center, or to toggle through the options, the machine cannot be in reverse. Mode 1 - Odometer The odometer records the miles traveled by the ATV. Mode 2 -Trip Meter The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button (override button) until the total changes to 0. NOTE: In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point. Mode 3 - Hour Meter This mode logs the total hours the engine has been in operation. Mode 4 - Tachometer The engine RPM is displayed digitally. NOTE: Small fluctuations in the RPM from day to day may be normal because of changes in humidity, temperature and elevation. 42

46 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit. To leave the diagnostic mode, either shift the machine out of neutral or turn the key switch off and on. NOTE: Any movement of the tires will also take the machine out of the diagnostic mode. To enter the diagnostics mode: 1. Turn the key switch off and wait 10 seconds. 2. Set the park brake and shift the transmission into neutral. 3. Hold the mode/reverse override button and turn the key switch on. 4. Release the switch as soon as the display is activated. The initial screen display refers to the software version installed in your ATV. This information is displayed briefly. Use the mode/reverse override button to toggle through the diagnostic screens. Screen 1: Battery voltage Screen 2: Tachometer Screen 3: AWD diagnostic This gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD). Screen 4: Gear circuit diagnostic This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. 43

47 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is set at 50 hours. You must enable the programmable service interval before it can be used. Once the service interval mode is set with the hours when service is due, the hours of actual engine operation are subtracted from the set hours until 0 is reached. When the counter reaches 0, the wrench icon will flash quickly for 5 seconds each time the vehicle is started as a reminder that the periodic maintenance is due. To set the hours, press and hold the mode/override button until the wrench icon flashes. When it begins to flash, release the button. The setting will increase by one hour each time the button is pressed. Pressing and holding the button will allow the numbers to escalate much faster. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set. NOTE: If you scroll past the intended number, hold the button down until the count turns over to 0. You can then reset the number. If the service interval is enabled on your ATV and you wish to turn it off, toggle to the service interval mode. Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center. Screen 6: Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display either kilometers or miles. The current display mode will be shown as KM or MP. To change, hold in the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set. 44

48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Special EFI Diagnostic Mode The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. To download blink codes (failure codes) from the EFI module: 1. Place the transmission in PARK, turn the engine off and turn the key switch to the ON position. 2. Turn the key switch off and on three times in less than five seconds, then leave the switch on. Any blink code numbers stored in the EFI module will display, one at a time, in the alphanumeric display. The number 61 and the word END will display after all codes have been transmitted. Blink Code Failure Description Blink Code Failure Description - No RPM Signal 54 Engine Temp Lamp: Open Load 21 Loss of Synchronization 54 Engine Temp Lamp: Short Circuit to Ground 45 Barometric Pressure Sensor: Circuit Low Input 46 Barometric Pressure Sensor: Circuit High Input 22 TPS: Open or Short Circuit to Ground 54 Engine Temp Lamp: Short Circuit to Battery 55 Diag Lamp: Open Load 55 Diag Lamp: Short Circuit to Ground 22 TPS: Short Circuit to Battery 55 Diag Lamp: Short Circuit to Battery 23 RAM Error: Defective ECU 56 Pump Relay: Open Load 42 Engine Temp Sensor Circuit: Short to Ground 42 Engine Temp Sensor Circuit: Open or Short to Battery 56 Pump Relay: Short Circuit to Ground 56 Pump Relay: Short Circuit to Battery 51 Injector 1: Open Load 41 Intake Air Temp Sensor: Open or Short Circuit to +Sensor Voltage 51 Injector 1: Short Circuit to Ground 41 Intake Air Temp Sensor: Short Circuit to Ground 51 Injector 1: Short Circuit to Battery 61 END 52 Injector 2: Open Load 52 Injector 2: Short Circuit to Ground 52 Injector 2: Short Circuit to Battery 45

49 OPERATION Fuel Safety Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not overfill the tank. Do not fill the tank neck. If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing. Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas. 46

50 OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully. CAUTION Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 synthetic Oil or another 0W-40 API certified SH oil. Never substitute or mix oil brands. 1. Fill the fuel tank with gasoline. See page Check the engine oil level on the dipstick. See page 71. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling. 4. Vary the throttle positions. Do not operate at sustained idle. 5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page Pull only light loads. 7. During the break-in period, change both the oil and the filter at 20 hours or one month. 47

51 OPERATION Pre-Ride Inspection If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it s in proper operating condition. Pre-Ride Checklist Item Remarks See Page Brake system / lever travel Ensure proper operation 34, 78 Brake fluid Ensure proper level 35 Auxiliary brake Ensure proper operation 37 Front suspension Inspect, lubricate if necessary 69 Rear suspension Inspect, lubricate if necessary 69 Steering Ensure free operation -- Tires Inspect condition and pressure 82,109 Wheels / fasteners Inspect, ensure fastener tightness 83 Frame nuts, bolts, fasteners Inspect, ensure tightness -- Fuel and oil Ensure proper levels 71 Coolant level (if applicable) Ensure proper level 76 Coolant hoses (if applicable) Inspect for leaks -- Throttle Ensure proper operation 33,102 Indicator lights / switches Ensure operation 32 Engine stop switch Ensure proper operation 32 Air filter, pre-filter Inspect, clean 84 Air box sediment tube Drain deposits whenever visible -- Headlamp Check operation, apply Polaris dielectric 85 grease when lamp is replaced Brake light / tail lamp Check operation, apply Polaris dielectric 88 grease when lamp is replaced Riding gear Wear helmet, goggles, protective clothing 10 48

52 Starting the Engine OPERATION Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface with the transmission in PARK. 2. Lock the park brake, sit on the vehicle and turn the engine stop switch to RUN. NOTE: Do not press the throttle while starting the engine. 3. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the vehicle starts. If the engine does not start, release the key, allowing it to return to the ON position, and wait five seconds. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts. CAUTION Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. Cold Weather Operation If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather. 49

53 OPERATION Hauling Cargo 1/3 2/3 Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner s manual and on the safety decals. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Do not obstruct the headlight beam with cargo. Belt Life Use low forward gear when hauling or towing heavy cargo to extend belt life. 50

54 Hauling Cargo OPERATION Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on one rack only increases the possibility of vehicle overturn. CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition. SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle. OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn. DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10 mph (16 kph) while towing a load on a level grass surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill. 51

55 OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Slowly depress the throttle with your right thumb and begin driving. Vehicle speed is controlled by the amount of throttle opening. 6. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces. 52

56 OPERATION Driving Safely Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse. NOTE: Practice making turns at slow speeds before attempting to turn at faster speeds. Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury. Avoid turning at sharp angles. Never turn at high speeds. 53

57 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Engage AWD before wheels begin to lose traction. 3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 4. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the rear wheels to stop spinning before engaging AWD, or engage AWD before wheels begin to lose traction. Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death. Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution. 54

58 Driving Safely Traveling Uphill OPERATION 25_ Maximum Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle. Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner s manual. 55

59 OPERATION Driving Safely Sidehilling Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner s manual. Sidehilling can be the most dangerous type of driving encountered and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions: 1. Slow down. 2. Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footrests. 3. Steer slightly into the hill to maintain vehicle direction. NOTE: If the vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately! 56

60 Driving Safely Traveling Downhill OPERATION Excessive speed when traveling downhill can cause loss of control and serious injury or death. When traveling downhill, follow these precautions: 1. Transfer your weight to the rear. 2. Drive straight down the hill. 3. Slow down. Squeeze the brake lever gradually. : Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control. Before operating your ATV, learn how the auxiliary brake works in case you lose your normal service brakes. 57

61 OPERATION Driving Safely Turning Around on a Hill Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner s manual. If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when you must turn around while climbing a hill is the K-turn: 1. Stop and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. 4. Staying uphill of the vehicle, turn the handlebars full left. 5. While holding the service brake, release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward. 6. Lock the parking brake and remount the vehicle from the uphill side, keeping body weight uphill. 7. Restart the engine with the transmission still in forward. 8. Release the parking brake and proceed slowly, controlling speed with the service brake, until the vehicle is on more level ground. 8 Uphill 58

62 Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water: OPERATION 1. Determine water depths and current before crossing. 2. Choose a crossing where 1 both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal. After running the vehicle in water, it s critical to have it serviced as outlined in the maintenance chart. See page 64. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings. CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine. NOTE: Avoid operating the vehicle through deep or fast-flowing water. If you cannot avoid water that exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes. If your vehicle becomes immersed, and it s impossible to take it to a dealer before starting it, follow the steps described on page 90. Have the vehicle serviced by your dealer at the first opportunity. 59

63 OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain. 60

64 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. NOTE: Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When it s safe to proceed, back slowly. Do not use the override switch unless additional power is required for vehicle movement. Use with caution. Avoid backing on inclines, and avoid turning at sharp angles. Your Polaris ATV is equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open the throttle just enough to maintain a desired speed. CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage. 61

65 OPERATION Driving Safely ParkingonanIncline Avoid parking on an incline if possible. If it s unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in park. 3. Set the parking brake. 4. Always block the rear wheels on the downhill side as shown. 62

66 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. Exhaust Emission Control System Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable. Crankcase Emission Control System This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. The system does not allow the blow-by gases to enter the atmosphere. Electromagnetic Interference This spark ignition system complies with Canadian ICES

67 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. See your Polaris dealer. Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed, heavy load operation S Extended idle S Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer. Maintenance Chart Key " Perform these procedures more frequently for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. 64

68 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) J Steering - Pre-Ride - Make adjustments as need- " Front suspension - Pre-Ride - ed. See Pre-Ride Checklist on page 48. " Rear suspension - Pre-Ride - Tires - Pre-Ride - " Brake fluid level - Pre-Ride - " Brake lever travel - Pre-Ride - Brake system - Pre-Ride - Wheels/fasteners - Pre-Ride - Frame fasteners - Pre-Ride - " Engine oil level - Pre-Ride - E " Air filter, pre-filter - Daily - Inspect; clean often E " E Air box sediment tube - Daily - Drain deposits when visible " E " J Coolant (if applicable) Headlamp/tail lamp/worklight Air filter, main element - Daily - Check level daily, change coolant every 2 years - Daily - Check operation; apply dielectric grease if replacing - Weekly - Inspect; replace as needed Recoil housing - Weekly - Drain water as needed, check often if operating in wet conditions Brake pad wear 10 H Monthly 100 (160) Inspect periodically Battery 20 H Monthly 200 (320) Check terminals; clean; test " Front gearcase oil 25 H Monthly 250 (400) Inspect level; change yearly (if equipped) " Rear gearcase oil (if equipped) 25 H Monthly 250 (400) Inspect level; change yearly " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services. 65

69 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) Remarks " Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly " Engine breather 25 H Monthly 250 (400) Inspect; clean if needed E filter (if equipped) " General lubrication Carburetor float bowl J E J E E " E " E J E J E Throttle Cable/ ETC Switch 50 H 3M 500 (800) Lubricate all fittings, pivots, cables, etc. 50 H 6M 500 (800) Drain bowl periodically and prior to storage 50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary Choke cable 50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary Carburetor air intake ducts/ flange 50 H 6M 500 (800) Inspect ducts for proper sealing/air leaks Drive belt 50 H 6M 500 (800) Inspect; adjust; replace as needed Cooling system (if applicable) 50 H 6M 1000 (1600) Inspect coolant strength seasonally; pressure test system yearly Engine oil change 100 H 6M 1000 (1600) Perform a break-in oil change at one month Oil filter change 100 H 6M 1000 (1600) Replace with oil change Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust Fuel system 100 H 12 M 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years " Radiator (if applicable) " Cooling hoses (if applicable) 100 H 12 M 1000 (1600) Inspect; clean external surfaces 100 H 12 M 1000 (1600) Inspect for leaks " Engine mounts 100 H 12 M 1000 (1600) Inspect Exhaust muffler/ 100 H 12 M 1000 (1600) Inspect pipe " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services. 66

70 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart J E J E Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed Ignition Timing 100 H 12 M 1000 (1600) Inspect " Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc. J J Clutches (drive and driven) Front wheel bearings 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts 100 H 12 M 1000 (1600) Inspect; replace as needed J Brake fluid 200 H 24 M 2000 (3200) Change every two years " J E Fuel filter 200 H 24 M 2000 (3200) Check for leaks around lines. Replace every 2 years, more often under extreme conditions. Spark arrestor 300 H 36 M 3000 (4800) Clean out E Idle speed - Adjust as needed J Toe adjustment - Inspect periodically; adjust when parts are replaced Headlight aim - Adjust as needed " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services. 67

71 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 68

72 MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Items not listed in the chart should be lubricated at the General Lubrication interval. Lubrication Guide Key " More often under severe use, such as wet or dusty conditions L Polaris Premium All Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special F Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging. Item Lube Method Engine Oil Polaris Premium 4 Add to proper level on dipstick. Synthetic 0W40 Brake Fluid DOT 3 Only Maintain level between fill lines. See page 35. Transmission Oil Polaris AGL Synthetic See page 73. Gearcase Lube Front Gearcase Oil Premium Demand See page 74. Drive Hub Fluid Rear Gearcase Oil ATV Angle Drive Fluid See page 75. (or GL weight gear lube) Front Prop Shaft Yoke (Fig. 1) FGrease Grease fittings (3 pumps maximum) Ball Joint (Fig. 2) "LGrease Locate fitting on back side of struts and grease with grease gun. (Fig. 1) (Fig. 2) 69

73 MAINTENANCE AND LUBRICATION Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. See page 107 for the part numbers of Polaris products. Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40 F. to 120 F. (-40 to +49 C.) Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption. Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified SH oil is allowable as long as it s 0W-40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer s recommendations for ambient temperature operation. CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 synthetic oil or another 0W-40 API certified SH oil. Never substitute or mix oil brands. 70

74 MAINTENANCE AND LUBRICATION Oil Level The oil dipstick and fill tube (1) is located on the engine and is accessible on the left side of the ATV. 1. Position the ATV on a level surface. 2. Start the engine and let it idle for seconds, then stop the engine. 3. Lift the lever lock (2) to remove the dipstick. Wipe it dry with a clean cloth. 4. Reinstall the dipstick completely, but do not lock it. The dipstick must be screwed completely in to keep the angle and depth of the stick consistent Remove the dipstick and check the oil level. Maintain the oil level in the safe range (3). Do not overfill. NOTE: Due to the dipstick entry angle into the crankcase, the oil level will read higher on the bottom side of the dipstick. Always read the level on the upper surface (4) of the dipstick. 6. After reinstalling the dipstick, be sure to seat the lever lock. 1 SAFE 3 4 ADD 8 OZ 71

75 MAINTENANCE AND LUBRICATION Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Run the engine for two to three minutes until warm. Stop the engine. 3. Clean the area around the drain plug. 4. Place a drain pan beneath engine crankcase and remove the drain plug. 5. Allow the oil to drain completely. 6. Replace the sealing washer on the drain plug. NOTE: The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches. 7. Reinstall the drain plug and torque to 20 ft. lbs. (27 Nm). 8. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove. 9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 10. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 11. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn. 12. Remove the dipstick and fill the sump with two quarts (1.9 l) of recommended oil. 13. Place the gear selector in park and set the parking brake. 14. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks. 15. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick. 16. Dispose of used filter and oil properly. 72

76 MAINTENANCE AND LUBRICATION Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Maintain the transmission oil level at the bottom of the fill plug hole (1). We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page 107 for the part numbers of Polaris products. 3 The transmission oil fill plug (2) is located on the right side of the ATV behind the footwell. The transmission drain plug (3), is located on the bottom left-hand side of the gearcase. Oil Check 1. Remove the footwell (see page 81). 2. Remove the fill plug and check the oil level. 3. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm). 4. Reinstall the footwell. Oil Change 1. Remove the footwell (see page 81). 2. Remove the drain plug and drain the oil into a drain pan. Dispose of properly. 3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm). 4. Remove the fill plug and add 15 oz. (450 ml) of the recommended transmission oil. 5. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm). 6. Check for leaks. 7. Reinstall the footwell

77 MAINTENANCE AND LUBRICATION Front Gearcase Oil Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. Maintain the oil level even with the bottom of the fill hole threads (1). We recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper operation of components. See page 107 for the part numbers of Polaris products. Oil Check 1. Position the ATV on a level surface. 2. Remove the fill plug (2) and view the oil level. 3. Add the recommended gearcase oil as needed to bring the level to the bottom of the fill hole threads. 4. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm). Oil Change 1. Position the vehicle on a level surface and remove the fill plug. 2. Place a drain pan beneath the gearcase, remove the gearcase drain plug (3) located on the bottom right-hand side, and drain the oil. 3. Clean and reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm). 4. Add 5 ounces (150 ml) of Polaris Premium Demand Drive Hub Fluid. 5. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm). 6. Check for leaks

78 MAINTENANCE AND LUBRICATION Rear Gearcase Oil The rear gearcase fill plug (1) is located on the rear of the gearcase. Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Maintain the rear gearcase 2 oil level (2) even with the bottom of the fill hole. We recommend the use of Polaris ATV Angle 1 Drive Fluid (or GL weight gear lube). See page 107 for the part numbers of Polaris products. Oil Check 1. Position the ATV on a level surface. 2. Remove the fill plug and view the oil level through the fill plug hole. 3. Add the recommended gearcase oil as needed. 4. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm). Oil Change 1. Place a drain pan beneath the drain and remove the drain plug (3). Catch and discard used oil properly. 2. Clean and reinstall the drain plug with a new sealing washer. Torque to 14 ft. lbs. (19 Nm). 3. Remove the fill plug and add 5 ounces (150 ml) of the recommended gearcase oil. 4. Inspect the oil level, which should be maintained level with the bottom of the fill plug hole. 5. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm). 6. Check for leaks. 3 75

79 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 107 for the part numbers of Polaris products. NOTE: Always follow the manufacturer s mixing recommendations for the freeze protection required in your area. Any time the cooling system has been drained for maintenance or repair, replace the coolant. If the recovery bottle has run dry, the level in the radiator should be inspected. Add coolant as needed. Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. 1. To access the radiator pressure cap, open the front box lid and pull open the access door. 2. Remove the pressure cap (1). 3. Using a funnel, slowly add 1 coolant through the radiator filler neck. 4. Reinstall the pressure cap, secure the access door and close the box. NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part. 76

80 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 81. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). Add coolant as needed. Cooling System Operation The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the engine, past the pressure cap, and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the bottle, past the pressure cap, and into the radiator. NOTE: Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle. 1 77

81 MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting. The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. After opening a bottle of brake fluid, always discard any unused portion. 1. Always keep brake fluid at an adequate level (see page 35). An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill. NOTE: Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill. 78

82 MAINTENANCE AND LUBRICATION Brakes 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5. Check the security and surface condition of the disc. NOTE: Replace brake pads when they arewornto3/64 (.1 cm). Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, the rear brake can be activated by depressing the foot pedal on the inside of the right footrest. The hydraulic auxiliary brake system requires no adjustment. NOTE: 3/64 (.1 cm) Since this is a rear brake only, it will not be as effective as the all-wheel single lever system. 79

83 MAINTENANCE AND LUBRICATION Toe Alignment Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8 to 1/4 toe out. 1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post. 2. Place stands (1) in front of the vehicle, perpendicular to the rear tires. See illustration. 3. Tie an elastic string around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle (2). 4. Measure the distance from the string to the rim at the front and rear of the front 1 rim (3). Rear measurement should be 1/16-1/8 (.2to.3cm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service. Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle

84 MAINTENANCE AND LUBRICATION Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 3. Pull the panel downward and rearward to remove it from the ATV. 4. Reinstall the side panel by reversing the removal procedure Footwell Removal 1. Remove the four screws (1) on the bottom of the footwell. 2. Use a flat screwdriver or sidecutters to remove the plastic rivets (2) securing the footwell to the fenders. 3. Remove the footwell

85 MAINTENANCE AND LUBRICATION Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the owner s manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth measures 1/8 (.3 cm) or less. Tire Tread Depth Always replace tires when tread depth is worn to 1/8 (.3 cm) or less. See illustration. 1/8I (.3 cm) Wheel Removal 1. Stop the engine, place the transmission in park and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel nuts and remove the wheel. 82

86 MAINTENANCE AND LUBRICATION Wheel Installation Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 1. Place the transmission in park and lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 3. Install the wheel nuts and finger tighten. 4. Lower the vehicle to the ground. 5. Torque the wheel nuts to specification. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service. Location Front Wheel Nuts Rear Wheel Nuts Torque 27 ft. lbs. (37 Nm) 27 ft. lbs. (37 Nm) Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. 83

87 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1. Remove the seat, release the air box cover clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry. 4. Reinstall the pre-filter over the main filter. (Replace the main filter if needed.) 5. Reinstall the filter into the air box and tighten the clamp. Do not over tighten the clamp, as filter damage could occur. 6. Reinstall the air box cover and the seat

88 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Allow lamps to cool before servicing. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Remove the screw from the rear of the pod. 3. Lift the pod slightly while depressing the tabs at the rear of the pod. 4. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 5. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring. 6. Turn the lamp counterclockwise to remove it. 7. Apply dielectric grease to the socket and install the new lamp. NOTE: Make sure the tab on the lamp locates properly in the housing. 8. Reassemble the pod. 85

89 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the engine and turn the headlight switch to high beam. 4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be two inches (5.1 cm) below the mark on the wall. NOTE: Include rider weight on the seat when measuring. 5. The adjustment knob is located on the right side of the headlight pod. Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise. Low Beam Adjustment The low beam can be adjusted slightly upward or downward. 1. Loosen the phillips screw (2) located at the rear of the headlamp. 2. Tilt the headlamp upward or downward. 3. Tighten the screw. 2 86

90 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 4. Unplug the headlamp from the wiring harness. 5. Use a small screwdriver to remove the o-rings from the headlight mounting tabs. 6. Pull the headlight housing up to release it from the locking tabs. 7. Lift the adjusting knob up to remove it from the locking tabs. 8. Carefully pull the assembly up and out of the pod. 9. Reverse the steps to install the new housing and reassemble the pod. NOTE: The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1/8 (13 cm). 10. Adjust the headlight aim by turning the adjusting knob. 51/8 (13 cm) 87

91 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) counterclockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Turn the headlight harness clockwise to secure the headlamp. Taillight/Brakelight/Worklight Lamp Replacement 1. Remove the harness 2 connector (1) from the back of the light assembly Turn the lamp (2) counterclockwise to remove it. 3. Apply dielectric grease to the socket and install the new lamp Reinstall the harness 1 connector. 5. Test the light for proper operation. 1 88

92 MAINTENANCE AND LUBRICATION Spark Plugs S S S Use RC7YC spark plugs. Proper electrode gap is.035 (.90 mm). Spark plug torque is 18 ft. lbs. (24 Nm). CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plugs for correct color. A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection. 1. Normal The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect fuel. 2. Wet Fouled The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil or incorrect throttle body adjustments. Spark Plug Removal and Replacement 1. Remove the spark plug cap. 2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove. 3. Reverse the procedure for spark plug installation. Torque to 18 ft. lbs. (24 Nm). 89

93 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it s impossible to take your ATV to a dealer before starting it, follow the steps outlined below. 1. Move the ATV to dry land or at the very least, to water below the footrests. 2. Check the air box for any water and dry it if it s wet. NOTE: Filter replacement is required if water is present. 3. Remove the spark plugs. 4. Turn the engine over several times using the electric start. 5. Dry the spark plugs and reinstall, or replace with new plugs. 6. Attempt to start the engine. If necessary, repeat the drying procedure. 7. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. NOTE: If water has been ingested into the PVT, follow the procedure on page 93 for drying out the PVT. 90

94 MAINTENANCE AND LUBRICATION Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000 F. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas. Never go under the vehicle while it s inclined. Use the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler. 1. Remove the arrestor clean-out plug (1) from the bottom of the muffler. 2. Place the transmission in PARK and start the engine Purge carbon from the system by momentarily revving the engine 1 several times. 4. If carbon is expelled, cover or plug the exhaust outlet (2) and rap on the pipe around the cleanout plug while revving the engine several more times. 5. If particles are still suspected to be in the muffler, elevate the rear of the vehicle one foot higher than the front. Set the parking brake and block the wheels. Make sure the vehicle is in PARK and repeat steps 3 and 4 until no more particles are expelled when the engine is revved. 6. Stop the engine and allow the arrestor to cool. Reinstall the arrestor plug and remove the outlet cover or plug. 91

95 MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch appliedtothe drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch. On Polaris ATVs, the approximate gear ratio difference between high and low range is 1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH (11 KPH), due to the system s dependence on engine speed. For example, when operating at a ground speed of 3 MPH (5 KPH) in low range, the engine speed would be around 3000 RPM. This is well above the engagement speed of RPM. However, in high range at 3 MPH (5 KPH), the engine would be running at only 1500 RPM. Whenever operating this close to the engagement speed, the engine may be running at a speed too low to provide the pinch needed to prevent belt slip. Belt slip is responsible for creating the excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. By switching to low range while operating at low ground speeds, the air temperature in the clutch cover is reduced by almost 160 degrees. Reducing the temperature inside the clutch cover extends the life of the PVT components (belt, cover, etc.). When To Use Low Range vs. High Range Following is a guideline for when to use low range and high range. Low Range S When basic operation is at speeds less than 7 MPH (11 KPH) S For heavy pulling S When operating in rough terrain (swamps, mountains, etc.) at low ground speeds High Range S When basic operation is at speeds greater than 7 MPH (11 KPH) S When operating at high ground speeds 92

96 MAINTENANCE AND LUBRICATION PVT System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components. The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe: Always follow all recommended maintenance procedures. See your dealer as outlined in the owner s manual. This PVT system is intended for use on Polaris products only. Do not install it in any other product. Always make sure the PVT housing is securely in place during operation. PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Remove the drain plug and allow the water to drain. Replace the drain plug. 2. Start the engine and shift the transmission into park. Apply varying throttle for seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds. 3. Allow the engine RPM to settle to idle speed, then shift the transmission to the lowest available range. 4. Test for belt slippage. If the belt slips, repeat the process. 5. Take the vehicle to your dealer for service as soon as possible. 93

97 MAINTENANCE AND LUBRICATION Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1. Disconnect the battery hold-down strap. 2. Disconnect the black (negative) battery cable first. 3. Disconnect the red (positive) battery cable last. 4. Lift the battery out of the ATV. Battery Installation When installing a new battery, make sure it s fully charged prior to its initial use. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 95 before installing the battery. 1. Ensure that the battery is fully charged. 2. Set the battery in the battery holder. 3. Connect and tighten the red (positive) cable first. 4. Connect and tighten the black (negative) cable last. 5. Attach the hold-down strap. 6. Verify that cables are properly routed. 94

98 MAINTENANCE AND LUBRICATION Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN ) or by charging about once a month to make up for normal self-discharge. Battery Tendert can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Do not ever pry the sealing strip off or add any other fluid to this battery. The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage. For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until thebattery voltage is 12.8 or greater. NOTE: When using an automatic charger, refer to the charger manufacturer s instructions for recharging. When using a constant current charger, use the following guidelines for recharging. An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. 95

99 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: State of Charge Always verify battery condition before and 1-2 hours after the end of charging. Voltage Action Charge Time* (Using constant current standard amps specified on top of battery) 100% volts None, check at 3 mos. from date of manufacture None required 75%-100% volts May need slight 3-6 hours charge, if no charge given, check in 3 months 50%-75% volts Needs charge 5-11 hours 25%-50% volts Needs charge At least 13 hours, verify state of charge 0%-25% 11.5 volts or less Needs charge with desulfating charger At least 20 hours 96

100 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 107 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning and safety labels are damaged, contact your a Polaris dealer for free replacement. CAUTION High water pressure may damage ATV components. Polaris recommends washing the ATV by hand or with a garden hose using mild soap. Certain products, including insect repellants and chemicals, will damage plastic surfaces. Do not allow these types of products to come into contact with the ATV. If a high pressure water system is used, exercise extreme caution to avoid damaging wheel bearings, radiator, transmission seals, body panels, brakes and warning labels. Grease all zerk fittings immediately after washing, and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system. Waxing the ATV Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of harsh cleaners since they can scratch the body finish. 97

101 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don t use harsh detergents or high pressure washers. Some detergents deteriorate rubber parts. Use dish soap type cleaners only. High pressure washers may force water past seals. Stabilize the Fuel Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) Allow minutes of operation for the stabilizer to disperse through the fuel in the tank. Oil and Filter Warm the engine and change the oil and filter. Air Filter / Air Box Inspect and clean or replace the pre-cleaner and air filter. Clean the air box and drain the sediment tube. Fluid Levels Inspect the following fluid levels and change if necessary: front and rear gearcases; transmission and brake fluid (change every two years or as required if fluid looks dark or contaminated). 98

102 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean, following the instructions on the can. Run the engine for several minutes so the Carbon Clean reaches the injectors. Turn the engine off. 2. Remove the spark plugs and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug holes, use a section of clear 1/4 hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. NOTE: Do this carefully! If you miss the plug holes, oil will drain from the spark plug cavities into the hole at the front of the cylinder head, and appear to be an oil leak. 3. Reinstall the spark plugs. Torque to 18 ft. lbs. (24 Nm). 4. Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs. 5. Turn the engine over several times. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil. 6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. Inspect and Lubricate Inspect all cables and lubricate. Follow lubrication guidelines in the Maintenance Section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease. Battery Maintenance Remove the battery and recharge it as outlined on page 95. Store the battery in a cool, dry place. Engine Anti-Freeze Test engine coolant strength and change if necessary. Coolant should be replaced every two years. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires 1-2 off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation. 99

103 MAINTENANCE AND LUBRICATION Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a like new appearance for many years. 1. Wash chrome rims frequently. Use a mild detergent to remove any salt, dirt, mud or grime. Never use abrasive cleaners on plated or painted surfaces. 2. Polish the clean chrome wheels periodically. Use an automotive grade chrome polish. 3. Routinely and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions. 4. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they re exposed to salt or other corrosive elements. Removing Corrosion If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the affected areas with the steel wool until the corrosion has been removed. Clean and polish the wheel as outlined above. Transporting the ATV Follow these procedures when transporting the vehicle. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Place the transmission in PARK and lock the parking brake. 3. Turn the fuel valve off and be sure the fuel cap, oil cap and seat are installed securely. 4. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets. 100